JP2009262505A - Manufacturing method of interior component for automobile, and mold for molding laminate structure - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of an interior component for an automobile in the whole or a part of which a laminate structure having a foamed resin base material and a resin rib integrated with its reverse surface, the method capable of solving problems of defective molding including warp deformation, wave deformation of a circumferential margin of a product and the like to enhance appearance design. <P>SOLUTION: A door trim 10 comprises an upper door trim (laminate structure) 20 and a lower door trim (resin single article) 30. The upper door trim 20 is composed of the laminate structure comprising a light-weight and shape-retainable foamed resin base material 21 and a resin rib 22 integrated with its reverse surface and having a predetermined pattern shape. When the foamed resin base material 21 is molded along a cavity shape by closing upper and lower molds 41 and 42, an air hose 44 blowing cooling air or a cooling block 45 is arranged in the outer circumferential space 427 of the cavity to prevent occurrence of a temperature difference between the temperature of the foamed resin sheet S in the inside and that of outside of the cavity. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a method for manufacturing automotive interior parts such as door trims, rear parcel shelves, floor trims, trunk trims, luggage trims, roof trims, rear side trims, etc., and a laminated structure constituting at least a part of the automotive interior parts. Automobile interior parts that are related to molding dies for molding, and that are particularly lightweight and can increase product rigidity, and eliminate the deformation associated with shrinkage distortion at the periphery of the product to enhance the appearance of the periphery. The present invention relates to a manufacturing method and a molding die for a laminated structure.

  Usually, automotive interior parts such as door trims, rear side trims, etc. are based on a heavy resin core with shape retention and mounting rigidity to the body panel. Generally, a structure with an excellent epidermis is attached. However, since a heavy resin core material is used, the weight of the product is increased, so that there is a problem in that fuel efficiency and attachment workability are deteriorated. Furthermore, as a molding method for molding this kind of interior parts, the mold is molded into the required shape by filling the molten resin into the mold, so the mold cost is high and the mass productivity is excellent even in terms of the molding cycle. I couldn't say that. In order to solve these drawbacks, recently, by using a foam resin material, it is possible to reduce the weight of the product, reduce the cost, and shorten the molding cycle. The forming method has been proposed.

  Next, a specific example using a foamed resin material will be described below, taking a door trim mounted on the interior side of a vehicle door panel as an example. FIG. 18 is a front view of the door trim 1, and FIG. 19 is a sectional view of the door trim 1. The door trim 1 is molded into a required shape, is lightweight and has a shape retaining property, and a load is applied. Applied to the surface of the foamed resin base material 2 and the resin rib 3 integrated with the back surface of the foamed resin base material 2 such as a portion where deformation is likely to occur and warpage deformation, wavy deformation, etc. It is comprised from the skin 4 which improves a surface feel and surface appearance. Accordingly, since the lightweight foamed resin base material 2 is used and the resin rib 3 is used only in a portion where rigidity is required, as shown in FIG. 20, less resin material is required, and weight reduction can be achieved structurally. .

  Further, as shown in FIG. 21, a molding die 5 used for the molding method of the door trim 1 includes a molding upper die 6 that can be moved up and down by a predetermined stroke, and a molding under the fixed side located below the molding upper die 6. It is comprised from the type | mold 7 and the injection machine 8 which supplies the material of the resin rib 3. As shown in FIG. More specifically, the molding upper die 6 is connected to the lifting cylinder 6a and is driven up and down by a predetermined stroke. The molding lower die 7 is provided with a manifold 7a and a gate 7b which are resin passages of molten resin from the injection machine 8. Is provided.

  When the molded upper and lower molds 6 and 7 are in the mold open state, the foamed resin sheet 2A, which is the material of the foamed resin base material 2, is heat-softened, and then placed in the molded upper and lower molds 6 and 7, as shown in FIG. As shown, the molded upper and lower molds 6 and 7 are clamped, and the foamed resin sheet 2A is press-molded into a required shape to form the foamed resin substrate 2. Further, in order to integrate the resin rib 3 on the back surface of the foamed resin base material 2 simultaneously with the molding of the foamed resin base material 2 or with a slight time difference, the molten resin M is supplied from the injection machine 8 to the manifold 7a, The resin rib 3 can be integrated with the back surface of the foamed resin substrate 2 in a predetermined pattern shape by injection filling the groove 7c of the molded lower mold 7 through the gate 7b and cooling and solidifying the molten resin M. The skin 4 may be laminated on the foamed resin sheet 2A in advance, or may be integrally formed by overlapping at the time of molding. The structure and molding method of the door trim 1 based on the foamed resin base material 2 are shown in detail in Patent Document 1.

JP 2005-238518 A

  Thus, the door trim 1 provided with the foamed resin base material 2 and the resin rib 3 integrated on the back surface thereof can achieve weight reduction, can be manufactured at low cost, and has the advantage of excellent productivity. On the other hand, the following problems have been pointed out. That is, as shown in FIGS. 21 and 22, the foamed resin sheet 2A is molded into a required shape by clamping the molded upper and lower molds 6 and 7, but as shown in FIG. 23, the foamed resin sheet 2a on the outer periphery of the cavity is formed. Is not cooled in a non-contact state with the mold surfaces of the molded upper and lower molds 6 and 7, and is in a heated state. After the mold upper and lower molds 6 and 7 are opened, the door trim 1 is opened as shown in FIG. Even after demolding, heat remains in the foamed resin sheet 2a around the cavity even after molding, so shrinkage distortion is likely to occur, and although this part is removed by the cutting process, there is a large possibility of adversely affecting the product periphery. This is a major factor in warping deformation and wavy deformation. Further, when trim trimming is performed after molding, when the door trim 1 is taken out of the mold, the foamed resin sheet 2a on the outer periphery of the cavity has heat (for example, the temperature is high and around 100 ° C.). In addition to being inferior in workability, the shape of this part is non-uniform, so that the setting work for the piercing type becomes complicated and the handling characteristics are inferior.

  The present invention has been made in view of such circumstances, and manufacture of an interior part for an automobile that employs, at least in part, a laminated structure provided with a foamed resin base material and a resin rib integrated on the back surface thereof. A method and a molding die for a laminated structure, which eliminates the occurrence of warp deformation, wavy deformation, etc. caused by shrinkage distortion at the peripheral edge of an automotive interior part, and has excellent appearance design and after molding An object of the present invention is to provide a method for manufacturing interior parts for automobiles with improved handling characteristics such as easy removal from a molding die and setting to a piercing die, and a molding die for a laminated structure. To do.

  In order to solve the above-mentioned problems, the present inventors have intensively studied, and as a result of the mold clamping of the upper and lower molds, the entrained whitened portion and the end material located at the cavity outer periphery of the foamed resin sheet molded into the cavity shape By forcibly cooling the part that is left standing with heat, such as the above, it becomes possible to adjust the temperature distribution inside and outside the cavity of the foamed resin sheet almost uniformly, and warp deformation and undulation deformation around the product periphery, etc. The present invention has been completed by paying attention to the fact that can be effectively eliminated.

  That is, the present invention is a laminated structure comprising a foamed resin base material that is molded into a required shape and is lightweight and has shape retention, and a resin rib having a predetermined pattern shape that is integrated on the back surface of the foamed resin base material. In a method for manufacturing an interior part for an automobile, in which the body is employed in whole or in part, the laminated structure is subjected to heat-softening treatment of a foamed resin sheet that is a material of the foamed resin base material, and then into a molding die. And mold the foamed resin base material into the required shape by clamping the molding die, and after clamping the molding die, the molten resin is injected and filled into the groove portion of the molding lower mold. While resin ribs with a predetermined pattern are integrated on the back side of the material, cooling air is blown from the air hose placed in the cavity outer peripheral space of the lower mold or the cooling block to the foamed resin sheet on the outer periphery of the cavity. Or by forcibly cooling the foamed resin sheet on the outer periphery of the cavity by contacting the cooling block, eliminating the temperature difference between the inside and outside of the cavity of the foamed resin sheet, and generating shrinkage strain at the peripheral part of the laminated structure It is characterized by avoidance.

  Here, the interior parts for automobiles can be applied to door trims, rear parcel shelves, floor trims, trunk trims, luggage trims, roof trims, rear side trims, and the like. The laminated structure according to the present invention can also be applied to the entire structure of the interior parts for automobiles, but only a part of the interior parts for automobiles, for example, the door trim upper in the upper and lower divided door trims, according to the present invention. A laminated structure can also be applied.

  Furthermore, the foamed resin base material having the shape retaining property can be obtained after the foamed resin sheet is heat-softened and then molded into a desired curved shape in a molding die, so that there is no reinforcing material such as a rib. , Has rigidity (shape retention) enough to retain the shape even when removed from the mold. Also, if the product shape includes a high expansion ratio part, after the foamed resin sheet is heat-softened, a vacuum suction mechanism is provided in the molding die and the foamed resin sheet is vacuumed along the inner surface of the molding die. A suction force may be applied.

  As the foamed resin sheet, a material obtained by adding a foaming agent to a thermoplastic resin is used. The thermoplastic resin may be one type of thermoplastic resin or two or more types of thermoplastic resins. Preferably, polyethylene resin, polypropylene resin, polystyrene resin, polyethylene terephthalate resin, polyvinyl alcohol resin, vinyl chloride resin, polyamide resin, polyacetal resin, polycarbonate resin, ionomer resin, acrylonitrile / butadiene / Styrene (ABS) resin or the like can be used. As the foaming agent, an organic foaming agent such as an azo compound, a sulfohydrazide compound, a nitroso compound or an azide compound, or an inorganic foaming agent such as sodium bicarbonate can be used. The foamed resin base material obtained by molding the foamed resin sheet into a required shape after heat softening treatment preferably has a foaming ratio of 2 to 10 times in consideration of the balance between the weight and strength of the product. The cell diameter of the foamed resin substrate at that time is preferably in the range of 0.1 μm to 2.0 mm, and the thickness is in the range of 0.5 to 30 mm, preferably 1 to 10 mm.

  Next, in order to improve the appearance design of the laminated structure, the skin may be laminated and integrated on the surface of the foamed resin base material. The material of the skin is not limited, but is composed of a top layer that enhances the surface appearance and a laminated sheet material of a cushion layer that imparts cushioning performance. The top layer includes a thermoplastic olefin (TPO) sheet and a thermoplastic. Synthetic resin sheets such as urethane (TPU) sheets and PVC sheets, or fabric sheets such as woven fabrics, non-woven fabrics, and knitted fabrics can be used. Polypropylene foam, polyethylene foam, polyurethane foam, etc. are used as the cushion layer. can do.

  On the other hand, the thermoplastic resin used as the resin rib can be appropriately selected from a wide range of thermoplastic resins. Usually, those that can be preferably used include polyethylene resins, polypropylene resins, polystyrene resins, polyethylene terephthalate resins, polyvinyl alcohol resins, vinyl chloride resins, polyamide resins, polyacetal resins, polycarbonate resins, ionomer resins, Examples include acrylonitrile / butadiene / styrene (ABS) resin. Moreover, you may mix various fillers in these thermoplastic resins. Examples of the filler that can be used include inorganic fibers such as glass fiber and carbon fiber, and inorganic particles such as talc, clay, silica, and calcium carbonate. Moreover, various additives, such as antioxidant, a ultraviolet absorber, a coloring agent, a flame retardant, and a low shrinkage agent, may be mix | blended. Furthermore, the said resin rib is arrange | positioned along the predetermined pattern shape on the back surface of a foamed resin base material. As an arrangement place, it arranges partially in the part where load concentrates, such as a peripheral part which tends to generate warpage deformation, undulation deformation, and a waist part and an armrest part where load is easy to apply.

  Next, a molding die used for molding a laminated structure used for all or part of an automobile interior part is molded into a required shape, and is a lightweight and shape-retaining foamed resin base material. , A molding die for a laminated structure used for molding a laminated structure provided with a resin rib having a predetermined pattern shape integrated with the back surface of the foamed resin base material, the molding die comprising: It is composed of an upper mold that can be clamped and opened and a lower mold, and an injection machine that is connected to the lower mold to supply molten resin. An air hose provided with an air blowing hole is piped, and when the foamed resin sheet is press-molded by clamping the upper and lower molds, cooling air is blown from the air blowing hole of the air hose to the foamed resin sheet on the outer periphery of the cavity. Forcing cooled foamed resin sheet of the cavity periphery by attaching, characterized in that so as to avoid the occurrence of shrinkage strain in the product periphery.

  Further, as a means for forcibly cooling the foamed resin sheet having the heat at the outer periphery of the cavity, it is possible to cool using a part of a cooling block or a molding die in addition to an air hose provided with an air blowing hole. The arrangement of the cooling block is limited to a case where the clearance between the upper and lower molds is constant on the outer periphery of the cavity, but the cooling efficiency is improved. As a material for the cooling block, a material having good thermal conductivity such as aluminum or copper is used.

  Therefore, according to the method for manufacturing an automotive interior part according to the present invention, the resin rib is integrated on the back side of the foamed resin base material having shape retaining property in order to reinforce the rigidity, and the weight is increased. Since the weight of the product can be reduced and the resin material can be saved without using the resin core material, the material cost can be reduced at the same time.

  Further, according to the method for manufacturing an automotive interior part according to the present invention, when the foamed resin sheet subjected to heat softening is press-molded along the cavity shape by clamping the upper and lower molds, the foamed resin sheet (wound around the cavity) is wound. By blowing cooling air to the inner surface of the mold or the end material), or by bringing the cooling block into contact with the forced cooling, there is almost no temperature difference inside and outside the cavity of the foamed resin sheet. No warp deformation, wavy deformation, etc. occur. Moreover, by cooling the outer peripheral part of the product, it can be easily taken out from the mold and has excellent handling characteristics when transported to the pierce mold.

  As described above, according to the method for manufacturing an automotive interior part according to the present invention, the laminated structure constituting the whole or a part of the automotive interior part is lightweight and has a shape retaining property. And the resin rib integrated with the back surface of the foamed resin base material, the conventional heavy resin core material can be eliminated, the weight can be reduced, and the manufacturing cost can be reduced. It has the effect of being excellent in productivity.

  Further, according to the method for manufacturing an automotive interior part according to the present invention, the foamed resin base material is molded along the cavity shape by clamping the molded upper and lower molds, and at the same time, cooling air is blown onto the foamed resin sheet on the outer periphery of the cavity. Alternatively, the foamed resin sheet on the outer periphery of the cavity is forcibly cooled by contacting the cooling block, eliminating the temperature difference between the inside and outside of the cavity, and adjusting the shrinkage rate to be approximately the same, thereby warping the peripheral edge of the laminated structure. Deformation, undulation deformation, etc. do not occur, the appearance design of the product periphery can be maintained well, and the cavity outer peripheral part can be cooled so that the mold can be removed from the mold smoothly after molding. It has the effect of excellent handling characteristics, such as the ability to smoothly set the piercing type.

  DESCRIPTION OF EMBODIMENTS Hereinafter, a preferred embodiment of a method for manufacturing automotive interior parts and a mold for forming a laminated structure according to the present invention will be described with reference to a method for manufacturing a vehicle door trim. It should be noted that the gist of the present invention is as described in the claims, and the contents of the embodiments described below are merely examples of the present invention.

  1 to 17 show an embodiment of the present invention. FIG. 1 is a front view showing a two-tone type automobile door trim manufactured by applying the method of the present invention, and FIG. 2 shows the configuration of the automobile door trim. 3 is a front view showing a resin rib and a door trim lower of a door trim upper in the door trim for the automobile, FIG. 4 is a transverse sectional view showing a configuration of the door trim upper, and FIGS. 5 and 6 are views of the door trim for the automobile. FIG. 5 is an explanatory view showing the entire configuration of the molding die, and FIG. 6 is an explanatory view showing a door trim upper corresponding part in the molding die. FIGS. 7 to 12 show the respective steps in the method for manufacturing the automobile door trim, FIG. 7 is an explanatory view showing the preheating process of the foamed resin sheet, and FIG. 8 is an explanatory view showing the setting process of the foamed resin sheet. 9 is an explanatory diagram showing the molding process of the foamed resin base material, FIGS. 10 and 11 are explanatory diagrams showing the forced cooling process of the foamed resin sheet on the outer periphery of the cavity, and FIG. 12 is an explanatory diagram showing the terminal processing process in the door trim upper. is there. Further, FIGS. 13 to 17 show modifications of the present invention, FIG. 13 is an explanatory diagram of a molding die, and FIG. 14 is an explanatory diagram showing a molding process of a foamed resin base material using the molding die. 15 is an explanatory view showing a forced cooling process of the foamed resin sheet on the outer periphery of the cavity, FIG. 16 is an explanatory view showing a process of conveying the door trim after molding to the pierce mold, and FIG. 17 is an explanatory view showing a further modification of the molding die. FIG.

  First, based on FIG. 1 thru | or FIG. 5, the structure of the two-tone type vehicle door trim 10 to which the structure of the interior component for motor vehicles which concerns on this invention is applied is demonstrated. The two-tone type automobile door trim 10 is composed of an upper and lower divided body including a door trim upper 20 made of a laminated structure and a door trim lower 30 made of a single resin. And as a functional component with which the door trim 10 is mounted | worn, the inside handle escutcheon 11 and the power window switch escutcheon 12 are attached to the door trim upper 20. FIG. The door trim lower 30 is provided with a door pocket opening 13, and on the back side thereof, as shown in FIG. 2, a pocket back cover (made of a resin molded body) 14 is attached. A speaker grill 15 is provided on the front side of the door trim lower 30 integrally with the door trim lower 30 or separately.

  By the way, the automotive door trim 10 according to the present invention is characterized by the structure of the door trim upper 20 formed of a laminated structure, and the weight of the product is reduced, and a good surface appearance and strong product rigidity are ensured. ing. That is, as shown in FIG. 2, the door trim upper 20 is formed into a desired curved surface shape, and has a foamed resin base material 21 having shape retention, and a resin rib integrated with the back surface side of the foamed resin base material 21. 22 and a skin 23 having a decorative function laminated and integrated on the surface side of the foamed resin base material 21. The skin 23 is made of a laminated sheet material in which a cushion layer 23b made of polypropylene foam is laminated on the back surface of a top layer 23a made of a TPO sheet.

  The foamed resin base material 21 has a shape after heat-softening treatment of the foamed resin sheet and heat molding into a required shape, for example, cold press molding with a molding die having a desired mold surface, so as to have shape retention. Is granted. The foamed resin sheet has a structure in which a foaming agent is added to a general-purpose thermoplastic resin. As the thermoplastic resin, a polyethylene resin, a polypropylene resin, a polystyrene resin, a polyethylene terephthalate resin, a polyvinyl alcohol resin, and vinyl chloride are used. Resin, polyamide resin, polyacetal resin, polycarbonate resin, ionomer resin, acrylonitrile / butadiene / styrene (ABS) resin, etc. can be used, and as foaming agents, organic foaming agents such as azodicarbonamide and sodium bicarbonate Inorganic foaming agents such as can be used. In this embodiment, a foamed resin sheet in which sodium bicarbonate is appropriately added as a foaming agent to a polypropylene resin is used. Moreover, the expansion ratio of the foamed resin base material 21 is set to 2 to 10 times, and the thickness is set to 0.5 to 30 mm, particularly preferably 1 to 10 mm.

  Next, as shown in FIG. 3, the resin ribs 22 are set in a lattice pattern extending in the vertical and horizontal directions or in an oblique direction. And this resin rib 22 consists of a general purpose synthetic resin molding which added reinforcing fibers, such as glass fiber and a natural fiber, and the synthetic resin which can be preferably used normally is polyethylene resin, polypropylene resin, polystyrene resin, polyethylene The present embodiment may be appropriately selected from terephthalate resin, polyvinyl alcohol resin, vinyl chloride resin, polyamide resin, polyacetal resin, polycarbonate resin, ionomer resin, acrylonitrile / butadiene / styrene (ABS) resin, etc. In view of environmental and recycling aspects, polypropylene resins are used.

  As described above, the door trim 10 shown in FIGS. 1 to 3 includes the door trim upper 20 made of a laminated structure and the door trim lower 30 which is a single synthetic resin, and has an excellent appearance design due to an accent effect on the appearance. It has sex. Furthermore, since the door trim upper 20 is composed of a foamed resin base material 21 having shape retention and a resin rib 22 integrated with the back surface of the foamed resin base material 21, the door trim upper 20 is formed on the entire surface of the product as in the past. The resin core material that has been occupied can be abolished and the lightweight foamed resin base material 21 is used. On the other hand, the resin rib 22 has a bone shape and is subjected to a load, such as a clip mounting seat, a waist flange, an armrest portion. The parts excluding the top surface have a thinned structure, so that the weight of the product can be reduced by 40% or more compared to the conventional example, and the resin material can be saved significantly. Can contribute to down. Furthermore, since the foamed resin base material 21 has a porous structure, the door trim upper 20 has excellent sound absorption performance and can reduce noise inside and outside the vehicle interior.

  Next, FIG. 4 is a cross-sectional view showing the main configuration of the door trim upper 20, and the door trim upper 20 has a predetermined pattern on the back surface of the foamed resin base material 21 that is lightweight and has shape retention. Shaped resin ribs 22 are integrated, and a surface 23 of the foamed resin base material 21 is laminated with a skin 23 having cushioning properties. And the peripheral part 24 of the door trim upper 20 does not have warp deformation, undulation deformation, or the like, and the appearance design is kept good. Moreover, the terminal process by which the winding white 25 was folded back on the back surface of the foamed resin base material 21 is performed.

  Next, the configuration of the molding die 40 for manufacturing the door trim 10 will be described with reference to FIGS. First, as shown in FIG. 5, the molding die 40 is connected to a molding upper mold 41 that can move up and down by a predetermined stroke, a molding lower mold 42 that is paired with the molding upper mold 41, and a molding lower mold 42. And two injection machines 43a and 43b. More specifically, the molding upper die 41 has a cavity portion 411 that matches the product shape, and is driven up and down by a predetermined stroke by an elevating cylinder 412 connected to the upper surface of the molding upper die 41. Guide bushes 413 are provided at the four corners of the molding upper die 41. On the other hand, the molding lower die 42 is provided with a core portion 421 corresponding to the cavity portion 411 of the molding upper die 41. In addition, manifolds 422a and 422b and gates 423a and 423b are provided to supply molten resin to the mold surface of the core portion 421. The injection machine 43a passes through the resin passages of the manifolds 422a and 422b and gates 423a and 423b. , 43b are supplied to the upper surface of the core portion 421. In order to form the resin rib 22, a groove portion 424 to which the molten resin M <b> 1 is supplied is formed on the upper surface of the core portion 421. A clearance cavity 425 is set. In addition, guide posts 426 serving as a guide mechanism protrude from the four corners of the molding lower die 42. The guide posts 426 guide the molding upper die 41 when the molding upper and lower dies 41, 42 are clamped. By guiding the guide post 426 into the bush 413, the pressing posture of the molding upper die 41 can be properly maintained.

  Further, as shown in FIG. 6, an air hose 44 is piped in the outer peripheral space 427 of the core portion 421 of the molding lower mold 42, and a plurality of air blowing holes 441 are opened in the air hose 44. The air hose 44 forcibly cools the foamed resin sheet Sa on the outer periphery of the cavity during the molding of the heat-softened foamed resin sheet S, thereby eliminating the temperature difference between the inside and the outside of the cavity, warping deformation, undulation deformation, etc. Used to eliminate poor appearance due to shrinkage distortion.

  Next, each process of the manufacturing method of the door trim 10 will be described. First, as shown in FIG. 7, the heater device 50 laminates the skin 23 on one surface of the foamed resin sheet S and heat-softens it to a predetermined temperature. In this embodiment, a polypropylene foam sheet (manufactured by Sumika Plustech, trade name: Sumiceller foam PP sheet, expansion ratio = 3 times, thickness 3 mm) is used as the foam resin sheet S.

  Next, as shown in FIG. 8, the heat-softened foamed resin sheet S (laminated with the skin 23) is formed in the cavity portion 411 of the molding upper die 41 and the core portion of the molding lower die 42 at the location corresponding to the door trim upper 20. Set in the upper half of the cavity defined at 421. If desired, the foamed resin sheet S and the skin 23 may be set so as to be separately stacked in the molding die 40. After setting the foamed resin sheet S, the molding cylinder 41 is driven to lower the molding upper mold 41 by a predetermined stroke, the molding upper and lower molds 41 and 42 are clamped, and the foaming resin sheet S becomes the desired mold surface. It is shaped along the shape (see FIG. 9).

  Furthermore, the injection molding of the resin rib 22 and the door trim lower 30 is performed simultaneously with the molding of the foamed resin base material 21 or after a lapse of a predetermined time. That is, when the molding upper and lower molds 41 and 42 are in the clamped state, the molten resin M1 is injected and filled into the groove 424 from the first injection machine 43a through the manifold 422a and the gate 423a, and the resin rib 22 is molded. In this embodiment, in order to mold the door trim lower 30 simultaneously with the molding of the resin rib 22, the molten resin M2 is injected and filled into the cavity 425 through the manifold 422b and the gate 423b from the second injection machine 43b. As the molten resins M1 and M2, Sumitomo Nobrene BUE81E6 (polypropylene manufactured by Sumitomo Chemical Co., Ltd., melt index = 80 g / 10 min) is used. Moreover, fillers such as talc may be mixed in the molten resins M1 and M2 at an appropriate ratio.

  As shown in FIGS. 10 and 11, the method of the present invention is characterized in that the heat-softened foamed resin sheet S is molded into a required shape by clamping the upper and lower molds 41 and 42, and at the same time the cavity outer peripheral space 427. The cooling air is blown from the air blowing holes 441 of the air hose 44 piped to the foamed resin sheet Sa in this portion, and forced cooling is performed. In this way, the foamed resin sheet Sa that is located in the cavity outer peripheral space 427 is forcibly cooled, thereby eliminating the temperature difference between the inside and outside of the cavity in the foamed resin sheet S, stabilizing the contraction at the outer periphery of the cavity, and warping deformation. It is possible to eliminate appearance defects such as undulating deformation.

  Also, when the door trim 10 is taken out after the mold upper and lower molds 41 and 42 are opened, the temperature of the portion located on the outer periphery of the cavity is lowered to about 60 ° C. due to forced cooling (previously 100 ° C.). As shown in FIG. 12, the setting operation when setting the piercing die 60 can be easily performed. Then, as shown in FIG. 12 (a), cut processing is performed by the piercing cut blade 61 along the trim cut line of the trim upper 20 in the door trim 10 set in the piercing die 60, and then shown in FIG. 12 (b). In this way, the winding white 25 may be wound and fixed on the back surface of the foamed resin substrate 21.

  As described above, according to the method of the present invention, the air hose 44 is disposed in the cavity outer peripheral space 427 of the molding lower mold 42, and the foamed resin sheet Sa positioned in the cavity outer peripheral space 427 is forcibly cooled simultaneously with the molding of the foamed resin base material 21. As a result, the temperature difference between the inside and outside of the cavity can be eliminated and the shrinkage rate inside and outside the cavity can be adjusted to be substantially the same, so that the vicinity of the peripheral edge portion 24 in the door trim upper 20 does not undergo warp deformation, undulation deformation, etc. There is an effect that the designability can be remarkably improved. Further, by forcedly cooling the foamed resin sheet Sa on the outer periphery of the cavity, the workability of taking out from the molding die 40 and the workability of setting to the piercing die 60 can be improved, and there is an advantage that the handling characteristics are excellent. .

  Next, FIG. 13 and FIG. 14 show a modification of the present invention. As shown in FIG. 13, instead of the air hose 44, a cooling block 45 is formed in the cavity outer peripheral space 427 with a mounting bolt 451. 42 is fixed. The cooling block 45 is made of a material having good thermal conductivity such as aluminum or copper. Therefore, also in this modification, when the foamed resin sheet S subjected to heat softening is put into the molds of the upper and lower molds 41 and 42 and the upper and lower molds 41 and 42 are clamped, the results are shown in FIGS. As described above, the foamed resin base material 21 is press-molded into a required shape, and at the same time, the foamed resin sheet Sa on the outer periphery of the cavity is forcibly cooled by contacting with the cooling block 45, and the temperature difference between the inside and outside of the cavity. Can be eliminated, the contraction of the foamed resin sheet Sa on the outer periphery of the cavity is stabilized, and the same effect as the above-described embodiment can be obtained. In addition, when the cooling block 45 is installed, it can be set only when a certain clearance between the forming upper and lower molds 41 and 42 is secured. When the cooling block 45 is used, as shown in FIG. 16, the shape of the foamed resin sheet Sa on the outer periphery of the cavity becomes uniform, and the incidental effect that the setting work to the pierce mold 60 is facilitated. There is. Further, instead of the structure in which the cooling block 45 is attached to the molding lower mold 42, as shown in FIG. 17, a cooling portion 428 for forcibly cooling the foamed resin sheet Sa on the outer periphery of the cavity can be set in the molding lower mold 42. .

  In the embodiment described above, the structure of the present invention is applied to the door trim upper 20 in the two-tone type automobile door trim 10, but the interior door trim or the interior parts other than the door trim, such as the rear parcel shelf, the floor trim, and the trunk trim. It can be manufactured by applying the method of the present invention to interior trims such as luggage trim, roof trim, rear side trim and the like.

It is a front view showing a two-tone type automobile door trim manufactured by applying the method of the present invention. It is the II-II sectional view taken on the line in FIG. It is a front view which shows the resin rib and door trim lower in the door trim upper after removing the foamed resin base material of the door trim upper in the door trim for motor vehicles shown in FIG. It is the IV-IV sectional view taken on the line in FIG. FIG. 2 is an overall view showing a configuration of a molding die used when molding the automobile door trim shown in FIG. 1. FIG. 6 is a sectional view taken along line VI-VI in FIG. 5. It is explanatory drawing which shows the preheating process of the foamed resin sheet in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the setting process of the foamed resin sheet in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the formation process of the foamed resin base material in the manufacturing method of the door trim for motor vehicles shown in FIG. FIG. 10 is a sectional view taken along line X-X in FIG. 9. It is explanatory drawing which shows the cooling form of the foaming resin sheet of the cavity outer periphery in the formation process of the foaming resin base material shown in FIG. It is explanatory drawing which shows the terminal process process in the manufacturing method of the door trim for motor vehicles shown in FIG. It is explanatory drawing which shows the modification of the shaping die used for this invention method. It is explanatory drawing which shows the formation process of the foaming resin base material using the shaping die shown in FIG. It is explanatory drawing which shows the cooling form of the foaming resin sheet of the cavity outer periphery in the formation process of the foaming resin base material shown in FIG. It is explanatory drawing which shows the terminal process process of the door trim for motor vehicles using the shaping die shown in FIG. It is explanatory drawing which shows the modification of the shaping die shown in FIG. It is a front view which shows the conventional door trim for motor vehicles. It is the XIX-XIX sectional view taken on the line in FIG. It is explanatory drawing which shows the pattern shape of the resin rib in the conventional door trim for motor vehicles. It is explanatory drawing which shows the shaping | molding method of the conventional door trim for motor vehicles. It is explanatory drawing which shows the formation process of the conventional door trim for motor vehicles. FIG. 23 is a sectional view taken along line XXIII-XXIII in FIG. 22. It is explanatory drawing which shows the fault of the conventional door trim for motor vehicles.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Two-tone type automobile door trim 20 Door trim upper 21 Foamed resin base material 22 Resin rib 23 Skin 23a Top layer 23b Cushion layer 24 Peripheral part 25 Roll-in white 30 Door trim lower 40 Molding die 41 Molding upper die 42 Molding lower die 427 Cavity Peripheral space 428 Cooling part 43a, 43b Injection machine 44 Air hose 441 Air blowing hole 45 Cooling block 451 Mounting bolt 50 Heater device 60 Pierce type 61 Pierce cut blade S Foamed resin sheet M1, M2 Molten resin

Claims (3)

A foamed resin base material (21) which is molded into a required shape and is lightweight and has shape retention, and a resin rib (22) having a predetermined pattern shape integrated with the back surface of the foamed resin base material (21). In the manufacturing method of the interior component (10) for automobiles, wherein the laminated structure (20) is adopted in whole or in part,
The laminated structure (20) is obtained by heat-softening the foamed resin sheet (S), which is the material of the foamed resin base material (21), and then charging it into the molding dies (41, 42). 41, 42) to mold the foamed resin base material (21) into a required shape, and after clamping the molding die (41, 42), in the groove (424) of the molded lower mold (42). The resin rib (22) having a predetermined pattern shape is integrated on the back side of the foamed resin base material (21) while the molten resin (M1) is injected and filled into the cavity outer peripheral space (427) of the molded lower mold (42). The cooling air is blown from the air hose (44) or the cooling block (45) disposed on the foamed resin sheet (Sa) around the cavity, or the cooling block is brought into contact with the foaming resin sheet (Sa) around the cavity. Foam By forcibly cooling the fat sheet (Sa), the temperature difference between the inside and outside of the cavity of the foamed resin sheet (S) is eliminated, and the occurrence of shrinkage distortion at the peripheral portion of the laminated structure (20) is avoided. A method for manufacturing interior parts for automobiles. A foamed resin base material (21) which is molded into a required shape and is lightweight and has shape retention, and a resin rib (22) having a predetermined pattern shape integrated with the back surface of the foamed resin base material (21). A molding die (40) for the laminated structure (20) used to mold the laminated structure (20),
The molding die (40) includes a molding upper die (41) capable of mutual clamping and mold opening, a molding lower die (42), and a molding lower die (42) for supplying molten resin (M1). And an air hose (44) provided with an air blowing hole (441) in the cavity outer peripheral space (427) of the molded lower mold (42), and a foamed resin. When the sheet (S) is press-molded by clamping the upper and lower molds (41, 42), cooling air is supplied to the foamed resin sheet (Sa) on the outer periphery of the cavity and the air blowing holes (441) of the air hose (44). A molding die for a laminated structure, wherein the foamed resin sheet (Sa) on the outer periphery of the cavity is forcibly cooled by spraying from above to avoid the occurrence of shrinkage distortion at the peripheral edge of the product. A foamed resin base material (21) which is molded into a required shape and is lightweight and has shape retention, and a resin rib (22) having a predetermined pattern shape integrated with the back surface of the foamed resin base material (21). A molding die (40) for the laminated structure (20) used to mold the laminated structure (20),
The molding die (40) includes a molding upper die (41) capable of mutual clamping and mold opening, a molding lower die (42), and a molding lower die (42) for supplying molten resin (M1). And a cooling block (45) with good thermal conductivity is arranged in the cavity outer peripheral space (427) of the molding lower mold (42), and is connected to the injection machine (43a). Simultaneously press-molding the softened foamed resin sheet (S) by clamping the upper and lower molds (41, 42), and forcibly bringing the foamed resin sheet (Sa) around the cavity into contact with the cooling block (45) Therefore, the foamed resin sheet (Sa) on the outer periphery of the cavity is formed into a shape that is easy to handle at a low temperature while eliminating shrinkage distortion due to a temperature difference between inside and outside of the product. Molding die.

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